Commissioning of the Hydrofinishing Unit (I)

The following aspects are mainly inspected: 1. Inspection of process pipelines 2. Inspection of valves 3. Inspection of reactors, towers, vessels, and heating furnaces 4. Inspection of heat exchange equipment 5. Inspection of compressors and pumps 6. Inspection of instruments and control systems 7. Overall inspection of the plant 8. External inspection of the plant

Pay attention to the protection of the catalyst during startup, as well as the issue of catalyst loading in the hydrogenation reactor

Let me give you an example: For instance, when inspecting a heating furnace, one checks the furnace tubes in accordance with the relevant inspection standards; one also inspects for any debris inside the furnace chamber, ensures that the furnace walls are smooth and free of cracks, and verifies that the heat-resistant lining, supports, elbows, explosion-proof doors, viewing ports, natural ventilation doors, and other accessories are in good condition； Check whether the valves of the gas pipelines for each burner, as well as the pipelines for fire-fighting steam and purge steam, are functioning properly, and ensure that the flame arrestors are installed in accordance with the specified requirements ； Whether the flue dampers, air valves, soot blowers, fans, and butterfly valves are flexible and functional. Special attention should be paid to checking the free expansion space for thermal expansion of the opposing furnace tubes, in order to prevent the tubes from bending due to thermal expansion after ignition. Special attention should be paid to indicating the valve direction on components such as flue dampers, to prevent accidental operation.

Detailed inspection plan: Chapter 2 Comprehensive Inspection of Unit Process Equipment, Section 1 Purpose of the Inspection: Before the hydrogenation unit is put into operation for trial running, a comprehensive inspection of the project quality must be carried out in accordance with the design requirements, to ensure the safe start-up and operation of the unit. 1. Check whether the process flow, automatic control flow, and public systems after the project is completed meet the design requirements and production needs of the facility. 2. Check whether the project quality meets the design specifications, and whether there are any defects or potential risks. 3. Check for any process modification projects ； 4. Check whether the pumps, hydrogen compressors, and other equipment are ready for commissioning. Section 2: Inspection Contents 1. Overall device 1.1 Whether the equipment is installed in accordance with the design requirements, whether all components are available, whether the construction quality meets the design standards, and whether the process flow complies with the specified requirements. 1.2 The device is vertically intact at ground level; the sewer wells, drainage ditches, underground tanks, underground cables, and manhole covers are all present in good condition. The office building, control room, power distribution room, compressor room, as well as the roads and floors are in good condition. The lighting and communication systems meet the design requirements. 1.3 Are there any issues with the process pipelines and individual equipment of each system? The construction of pipe bridges, pipe racks, pipe supports, pipe hangers, pipe clamps, insulation systems, heat tracing systems, ladders, guardrails, frames, platforms, etc., meets the required standards, being firm and undamaged. 1.4 Check whether fire-fighting equipment, fire protection facilities, personal protective equipment, and gas masks are available and in good working condition, and whether safety and fire escape routes are unobstructed. 2. Process pipelines 2.1 Check each process pipeline according to the process flow diagram, following its path, to verify whether the connections to and from the equipment meet the requirements. 2.2 Whether the material diameter of the process pipelines, as well as the materials of valves, flanges, gaskets, bolts, and nuts, meet the design requirements. 2.3 Alloy pipelines, fittings, and accessories in high-temperature and high-pressure systems shall be identified using spectroscopy. Ultrasonic thickness testing shall be conducted on both alloy pipelines and thick-walled carbon steel pipes used in such systems, to ensure the accuracy of the material composition and wall thickness; a dedicated person shall be assigned to carry out these inspections. 2.4 Check whether the valves, check valves, safety valves, control valves, steam traps, flow orifice plates, pressure gauges, blind flanges, and other components on the process pipeline are installed correctly; ensure that all valves have been pressurized, that the packing in the valves is properly installed, that the valves operate smoothly, and that all bolts are tightly secured. 2.5 The pipeline has passed the hydrostatic test, the welds meet the design specifications, and the construction records are complete. 2.6 The process pipelines shall be anti-corrosion treated, painted, insulated, and provided with heat tracing in accordance with design specifications. 2.7 Check the process pipeline for any incorrect wiring. 3. Pumps 3.1 Are the nameplates complete and accurate, and do the parameters match those of the equipment? 3.2 The foundation base of the pump is stable, intact, and smooth, with the anchor bolts fully tightened. Waste discharge is reasonable. 3.3 The oil cups, oil level gauges, check valves, pressure gauges, guards, and grounding wires meet the design requirements and are reliable and functional. 3.4 The pump is fully painted and has a shiny finish. 3.5 The inlet and outlet valves of the pump, as well as the pipelines for cooling water, seal oil, flushing oil, and lubricating oil, are all properly installed. 3.6 The trial operation seal should be properly installed, and the mechanical seal should be ready. 3.7 The inlet and outlet valves, check valves, and filters of the pump are installed correctly. 4. Compressors 4.1 The quality of installation for the new hydrogen compressors and circulation compressors shall be checked in accordance with the installation drawings. 4.2 The pressure gauges, thermometers, control levers, control panels, load regulators, etc., have all been calibrated and are functioning properly. 4.3 The oil injector and lubricating oil station work well. 4.4 The nitrogen seal line, cooling water line, and grounding wire are properly installed. 4.5 The inlet and outlet valves, check valves, safety valves, and filters are properly installed and function smoothly. 4.6 The self-protection system for compressor oil pressure and temperature functions well. 4.7 The foundation is solid and intact. The bolts are fully tightened. 5. Heating furnace 5.1 The material and structure of the furnace tubes meet the design requirements. 5.2 Check whether the induced draft fan is installed correctly. 5.3 Check whether the outer surface of the furnace tube is smooth and clean, and whether there are any severe rust, pitting, peeling, or similar defects. The furnace lining and chimney show no severe cracks or peeling, and the expansion joints meet the requirements. 5.4 The vacuum gauge, temperature measurement points, viewing ports, explosion-proof doors, fire suppression systems, burners, and air valves should be in good condition, and the pressure measurement pipes must be unobstructed. Are the flue gas sampling ports and fire steam connections complete and in good working condition? 5.5 Check whether the flue baffle switch operates smoothly, whether the opening degree of the flue baffle matches the indicated position, and whether lubricant has been applied to the steel ropes and all rotating parts. 5.6 Check whether the burner nozzles are aligned in the center, and look for any deviation, bent ducts, or clogged nozzles. 6. Tower 6.1 According to the general assembly drawing, check whether the orientation and number of openings in the tower are in accordance with the design. The internal components of the tower are complete with no detachment, and the material quality and installation standards meet the requirements. 6.2 Check the inlet and outlet pipelines connected to the tower to ensure that the valves (especially the flow direction of check valves) are installed correctly, and that pressure gauges, level gauges, safety valves, vent valves, etc. are present and in good working condition. Check whether the lead seal of the safety valve is intact and meets the process requirements. 6.3 Check whether the gaskets of the tray are properly installed, whether the bolt clamps are tight, whether the threads are damaged, and also verify that elements such as the vapor rise distributor tray and the liquid spray nozzles are in the correct positions. Check that the scaffolding used during installation inside the tower and other debris have been cleared away. 6.4 Check whether the foundation bolts use double nuts and whether there is full engagement; also inspect the tower structure and all its components for any signs of collision, damage, or severe rust. Check the static grounding condition. 6.5 Ensure that all manholes on the tower wall are properly tightened; check that there are sufficient gasket bolts and that the installation is correct. Is the tower’s insulation in good condition, and is the paint up to standard? 7. Heat exchange equipment 7.1 Is the nameplate intact? Does the information on the nameplate match the equipment? 7.2 Check whether the installation is vertical and secure, and whether the foot bolts and static grounding are in good condition. 7.3 Check the shell surface for defects such as deformation, dents, cracks, rust, and pitting, and verify that there are no air leakage holes in the reinforcement plates of the connectors. The weld shall be free from cracks, slag inclusions, and pores, with undercut not exceeding 0.5 mm. 7.4 Check whether there are sufficient flange fastening bolts, whether their specifications are consistent, and whether there are any issues such as incomplete tightening, loose connections, cracks, or other damages. 7.5 Insulation and painting shall comply with the regulations. 7.6 Check whether the protective covers of each air cooler fan are in good condition, whether the motors, pulleys, and fans are properly installed and aligned, whether the belts are too loose or too tight; rotate the fan to verify that there is no collision or uneven tension during operation. 7.7 Manually operate the blinds to check whether the switches function smoothly, and whether the opening degree of the blinds matches the indications. Use the manual control system to increase or decrease the air pressure step by step, and observe the changes in the fan angle. 7.8 Check the pipe manifold for any deformation, bending damage, as well as cracks, pitting, rough surfaces, and rust. Check that the bellows plate is installed tightly and in accordance with requirements, and any debris inside the bellows should be removed. 7.9 Check whether the warped tube is compressed and deformed or bent. 7.10 Check whether the vent ports, sampling ports, inlet and outlet pressure gauges, and thermometers meet the production requirements. 8. Pressured vessels 8.1 Is the nameplate complete, and does its content match the equipment? The container material and the installation of components meet the design requirements. 8.2 The container shall not be deformed; the foundation and supports must be secure, and the bolts must be tightened. Are the foundation bolts and static grounding up to standard? 8.3 Check whether the openings and connections of the container meet the process requirements, as well as the flow direction of the valves; in particular, ensure that check valves and globe valves are aligned with the process flow direction. 8.4 Is the surface of the housing smooth and straight, free from dents, deformations, and damage caused by poor manufacturing or collisions during installation? 8.5 Check the inspector wall and welds for cracks, slag inclusions, pitting, and severe rust; the root penetration shall not exceed 0.5 mm. 8.6 Check whether the flange sealing surface is smooth without scratches, whether the gaskets are installed correctly, whether the material specifications meet the requirements, whether the flanges are aligned properly, and whether there is any misalignment or skewing. 8.7 Check whether the bolt specifications and materials of the connection flanges (including manholes and pipes) meet the requirements, whether the tightening force is consistent, and whether there is any under-tightening or loose fastening. 8.8 Check the installation of the internal components and ensure that any debris inside has been removed. 8.9 Whether the installation of level gauges, pressure gauges, temperature gauges, and vent valves meets the requirements. 8.10 Check whether the set pressure value of the safety valve meets the process requirements, and whether the lead seal is intact. 8.11 The raw material filter must be installed in accordance with the design requirements. 9. Reactor 9.1 Visual inspection of the reactor 9.1.1 Check for cracks or damage to the reactor foundation ； Are the anchor bolts tightened properly, and are double nuts being used? ； Check for any full buckling, as well as any tilting of the reactor. Check whether the nameplate is intact and accurate, and whether the static grounding meets the requirements. 9.1.2 Before installing the insulation layer, the shell wall (especially at the welds) and the openings for connecting pipes should be carefully inspected for any defects such as cracks, pitting, and damage. 9.1.3 Carefully inspect the bolts and nuts on each flange surface to ensure that their materials meet the requirements, and that their specifications (including bolt length) are consistent and in accordance with the standards; no bolts from different groups should be installed incorrectly or mixed together. Check the bolts and nuts for defects such as bending and cracks, and inspect the heads for any cracks or damage. After installation, the bolts should protrude by at least two to three threads; there should be no full-thread or slippage. 9.1.4 Before installation and resetting, check whether the gaskets on each flange surface meet the material requirements; inspect their surfaces for any deposits, rust, scratches, etc., and assess the surface finish. Installation is not permitted if there are radial scratches or insufficient finish and other defects. 9.1.5 Check whether the specifications, length, grade, and orientation of the flanges at each opening connection meet the requirements specified in the drawings, as well as whether the reinforcement at the openings is adequate. 9.1.6 Check whether the fire protection layer of the reactor cluster foundation meets fire safety requirements. 9.1.7 Whether the ladders, platforms, and supports of the reactor meet the installation requirements, and whether normal operation and maintenance are convenient and reliable. 9.2 Internal inspection of the reactor 9.2.1 Carefully inspect the surface of the surfacing layer for cracks, pitting, rust, and damage; special attention should be paid to the corners where the support rings and connectors meet. 9.2.2 Check whether the material and specifications of various internal components meet the design requirements, whether there is any deformation, cracks, or damage in these components, and whether their installation positions are appropriate. 9.2.3 Check the installation of the distribution disk, cold hydrogen disk, and support ring. Check whether the installation positions of the clamps and shims meet the requirements, and whether the bolts are tightened evenly and properly. 9.2.4 Check whether the nuts on the distribution plate are securely tightened. 9.2.5 Check whether the installation of the outlet collector meets the requirements, whether the specifications of the stainless steel mesh conform to the design requirements, and whether there are any signs of damage. 9.2.6 Check whether the installation of the thermocouple meets the requirements, for any signs of bending damage, and whether the support is reliable. 9.2.7 Check whether the installation of the catalyst unloading pipe inside the reactor meets the requirements. 9.2.8 Check whether the final inspector is clean. 10. Inspection of other equipment 10.1 All instruments in the entire system are properly installed and meet the design requirements; the model specifications and installation direction of the control valves also comply with the specified standards. 10.2 Are all control circuits of the DCS in accordance with the design requirements, and are the detection points correct? All control valves operate flexibly and effectively. After being integrated into the DCS system, check the operation of all instruments; compare and verify the indication values of the main instruments, and there should be no abnormalities. All control circuits must be calibrated and found to be satisfactory. 10.3 Are the alarms for flammable and explosive gases installed as required by design and functioning properly? Have all the alarm systems and indicator lights been installed completely, with no missed connections or similar issues? 10.4 Check whether all primary instruments (level gauges, flow meters, thermocouples, differential pressure gauges) are installed in accordance with requirements and whether their indications are correct. 10.5 The heating furnace, feed pump, hydrogen compressor, and emergency venting safety interlocks are functioning properly. 10.6 All electrical equipment enclosures shall be equipped with nameplates to indicate whether they meet the design and manufacturing requirements; explosion-proof electrical equipment shall have distinct explosion-proof markings, and all of them shall come with a factory certification of conformity. Enclosed electrical equipment shall be properly sealed. Check whether all equipment such as control circuits, measuring elements, control valves, field instrument cabinets, field gauges, and gauge boxes are present, and whether the markings are correct and clear. 10.7 Check whether the operation of each control valve is smooth and flexible, whether there is any looseness or sticking, and whether it can be fully opened and fully closed. 10.8 Check all electrical equipment (motors, electrical switches) for any defects such as damage or poor insulation of the cable grounds caused by construction work. 11. Inspection of safety facilities 11.1 Check the pipes of the fire suppression system against the drawings to ensure that the installation of fire-fighting equipment meets the requirements, that flanges and joints are properly sealed, and that valves and nozzles function smoothly. 11.2 Check whether the fire-fighting equipment at each fire station is complete. 11.3 Check whether the piping of the fire steam system meets the requirements, and whether the number of steam connection points is sufficient to meet fire protection needs and facilitates operation. 11.4 Check whether the fire alarm system and communication facilities have been installed and are functioning properly. Are the fire roads unobstructed? 11.5 Is the safety valve set at the specified pressure and fully sealed with lead seals?

We are adding a hydrogenation unit this year. Thank you to all the colleagues who provided us with the information; it has been extremely useful for us.

Comprehensive Inspection of the Equipment I. Explanation The comprehensive inspection of the equipment in question focuses on the thorough inspection of static process equipment. Check whether the system provides water, electricity, steam, air, fuel, etc. to the unit, and whether the unit is ready to begin comprehensive purging, flushing, and individual unit tests. It is necessary to confirm that the following production preparation tasks have been completed: 1. The construction unit has passed its own quality inspections, and a professional quality assessment team organized by the project contractor has conducted an initial evaluation of the project quality in accordance with relevant standards, and it has passed this evaluation. 2. Equipment such as towers and containers has been inspected and approved, with the manholes properly sealed. 3. The valve screws of the entire unit have had rust removed and lubricated; the switches operate smoothly, and any missing handwheels have been replaced. 4. The production scheduling system has ensured the availability of water, electricity, steam, air, nitrogen, fuel, and chemical raw materials in accordance with the required quantities, parameters, and timing. 5. The supplies department has stocked all the spare parts required during the testing process. 6. The fire-fighting facilities within the device are fully equipped. 7. Debris from the gutters and septic tanks has been removed, the drainage pipes have been flushed to check for blockages, and the manhole covers have been replaced. The painting and insulation of the pipes are basically complete. 8. The construction party shall remove all orifice plates, control valves, pressure gauges, and oil gauges from the unit, and store them properly so that they can be reinstalled after the pipelines have been purged and flushed. 9. The construction unit shall prepare filter screens of various specifications for the pump inlet. 10. The construction unit shall remove the temporary equipment and part of the scaffolding that are not needed during individual machine testing, ensuring that the work area is clean, all materials are removed, the site is tidy, and the roads are unobstructed. II. Equipment inspection items 1. Reactor (1) Visual inspection of the reactor A. The reactor foundation shows no cracks or damage ； Are the anchor bolts tightened? ； Are double nuts used? ； Check for any issues with unaccounted deductions, as well as any skewing in the reactor. Check whether the nameplate is intact and accurate, and whether the static grounding meets the requirements. B. Before installing the insulation layer, the shell wall (especially at the welds) and the openings for connecting pipes should be carefully inspected for any defects such as cracks, pitting, and damage. C. Carefully check whether the materials of the bolts and nuts on each flange surface meet the requirements, and whether their specifications (including bolt length) are consistent and compliant; no bolts from different groups should be installed incorrectly or mixed together. Check the bolts and nuts for defects such as bending and cracks; inspect the nuts for any cracks or damage. After installation, the bolts should protrude by at least two to three threads, and there should be no situation where they do not fully seat or slip. D. Before installation and reset, check whether the octagonal gaskets on each flange surface meet the material specification requirements; inspect their surfaces for any deposits, rust, scratches, etc., and examine the surface finish. Installation is not permitted if there are defects such as radial scratches or insufficient finish. E. Check whether the specifications, lengths, and grades of each startup connection flange, as well as their orientation, meet the requirements specified in the drawings, and whether the strength of the welds made at the openings meets the required standards. F. Check whether the fireproof layer of the reactor skirt meets fire protection requirements. G. Whether the ladders, platforms, and supports of the reactor meet the installation requirements, and whether normal operation and maintenance are convenient and reliable. (2) Internal inspection of the reactor: A. Carefully inspect the surface of the surfacing layer for cracks, pitting, rust, and damage; pay special attention to the corners where the support rings and connectors meet. If possible, the ferrite content should be checked again (mainly on the outside of the surfacing). B. Check whether the materials and specifications of various internal components meet the design requirements, whether there is any deformation, cracks, or damage in these components, and whether their installation positions are appropriate. C. Check the installation of the distribution disk, cold hydrogen disk, and support ring; verify whether the positions of all clamps and gaskets are appropriate, and ensure that the bolts are firmly tightened evenly. D. Check whether the nuts on the distribution plate are tightened properly. E. Check whether the installation of the outlet collector meets the requirements, whether the specifications of the stainless steel wire mesh comply with the design requirements, and whether there are any signs of damage. F. Check whether the installation of the thermocouple meets the requirements, for any signs of bending damage, and whether the support is reliable. G. Check whether the installation of the catalyst unloading pipe inside the reactor meets the requirements. H. After installing the dirt basket, check whether the chain length meets the requirements. I. Check whether the inspector is clean. 2. Tower (1) According to the general assembly drawing, check whether the opening, orientation, quantity, and specification grade of the tower are consistent. (2) Check whether the inlet and outlet pipelines connected to the tower, as well as the valves (especially the flow direction of check valves), are installed correctly, and whether pressure gauges, level gauges, safety valves, vent valves, etc. are fully installed and in good working condition. (3) Check whether the installation of the platform and ladder meets the requirements, and whether there are any areas that hinder operation and maintenance. (4) The welds on the tower walls and connections must meet the following requirements: A. No cracks, no slag inclusions, and no dense pores or sand holes. B. No arc pits or droplets. C. The weld shall be uniform without any unevenities or depressions, and the root penetration depth shall not exceed 0.5 mm. (5) Check the levelness of the tray; the difference between its lowest and highest points should be within the following ranges: For tower diameter of 1500mm to 2500mm, this difference is 4.5mm; for tower diameters of 2500mm to 4500mm, it is 6.0mm. (6) Verify that the height and levelness of the overflow weir meet the following requirements: The allowable height tolerance is ±1.5mm for tower diameters ≤3000mm, and ±3.0mm for diameters >3000mm. As for levelness, the difference between the highest and lowest points on the upper edge is 4.5mm for tower diameters of 1500mm to 2500mm, and 6.0mm for diameters >2500mm. (7) Check that the height of the surface of the tray plate at the lower end of the liquid drop plate is within an error range of 3.0mm. (8) The allowable deviation in the levelness at the top of the lift pipe is as follows: for tower diameter ≤3000mm, it is 30mm at most; for diameters >3000mm, it is 1% of the inner diameter of the tower. (9) Check whether the floating valve functions properly, and ensure there is no sticking, poor mobility, or issues such as broken parts or missing components. (10) Check that the scaffolding used during installation inside the tower and other debris have been cleared away. (11) Check whether the gasket of the tray is properly installed, whether the bolt clamps are tight, whether the threads are damaged, and also verify that the positions of other components such as the gas lift distributor tray and the liquid drop tube are correct. (12) Check whether the insulation of the tower is in good condition, whether the metal sheets are intact and reliable, and whether the paint meets the requirements. (13) Check whether the foundation bolts use double nuts and there is any under-tightening; inspect the tower and all its components for any signs of collision, damage, or severe rusting. (14) Check the static grounding condition. (15) Check whether the nameplate is intact and whether the information indicated matches the equipment. 3. Heating Furnace (1) Inspection of the furnace body section A. Refer to the installation diagram to check whether all components are installed correctly and whether the connections are secure. B. Explosion-proof doors, sight holes, thermocouples, flue gas sampling ports ； Are the fire steam pipes complete, in good working condition, and intact? C. Check whether the flue damper switch operates smoothly, whether the opening degree of the damper matches the indicated position, and whether lubricant has been applied to the steel cables and all moving parts. D. Whether the platform ladder is sturdy, and whether it is easy to operate and maintain. E. The markings are clear; is the paint up to standard? (2) Inspection of furnace tubes (including convection tubes) A. Check whether the tube support and guide tube assemblies are properly aligned and secure. B. Whether the residual gap resulting from the thermal expansion of the furnace tubes meets the requirements, and whether there are any blockages in the guide devices at the bottom of the tubes, etc. C. Is the outer surface of the furnace tube smooth and clean, free from severe rust, pitting, peeling, or similar defects? D. Inspect the weld: a. Reinforcement thickness; b. The weld and the surrounding base material must be free of cracks, pores, gas holes, slag inclusions, etc., and spatter, slag, and weld beads should be polished off using a grinder or wire brush. c. The depth of the chipped edge shall not exceed 0.5 mrn, and it must be smoothed out using tools such as grinding wheels. E. Whether there are any damages such as bending or deformation due to collisions during construction. F. Check whether the wall temperature measuring thermocouple is installed correctly, and whether the tube guide is too tightly constrained. G. Check whether the gaskets at the inlet and outlet of the furnace tubes as well as those on the purging flanges are properly installed, and whether the bolts are tightened to the required standard. (3) Inspection of the burner A. Check whether the burner nozzle is aligned in the center, and look for any deviation, bent ducts, or clogged nozzles. B. Check whether the oil and gas as well as steam connections are properly installed, whether the valve positions are correct, whether the drain facilities are adequate, and whether the gaskets at the sealing areas and the valve packing are properly installed. C. Whether the primary and secondary air dampers are flexible and functional. (4) Inspection of the fire-resistant insulation lining: Check whether the surface of the fire-resistant layer is smooth, for any signs of loosening, and whether the thickness of the heat-resistant layer is uniform. (5) Inspection of the flue A. Check whether the flue butterfly valve operates smoothly and properly, and whether the valve’s opening degree matches the indicated position. B. Check whether the insulation layer on the inner surface of the flue is smooth, and whether there are any large cracks or bulging, as well as any debris inside the flue. C. The markings should be clear, and the appearance must meet the requirements. D. Is the static grounding of the chimney in good condition? (6) Inspection of the air preheater. (7) Check whether the quick-opening door is flexible and can be closed tightly. (8) Check whether there is any sticking in the butterfly valve on the air duct, and ensure that there are markings indicating the opening and closing positions (i.e., markers showing the fully open and fully closed states). (9) Check whether the interlock is working properly. (10) For this fan motor, it is necessary to check whether the foundation is secure, whether the coupling connections are firm, whether the circulating water is connected, and whether the lubricating oil has been properly applied. (11) Check the construction quality of the air ducts and whether the insulation is securely installed. 4. Heat exchanger: (1) Is the nameplate complete, and does the information on the nameplate match the equipment? ； (2) Is the installation vertical and secure, and are the foot bolts and static grounding in good condition? ； (3) Check whether there is any deformation on the shell surface, as well as defects such as dents, cracks, rust, and pitting; also check whether the head has any air leakage holes ； (4) Whether the number, specifications, and location of the openings meet the requirements. (5) Do the welds meet the requirements? A. No cracks, slag inclusions, or pores ； B. Droplets, splashes, and temporarily fixed solder joints should be removed ； C. The edge bite should not exceed 0.5 mm. (6) Are the flange surfaces smooth and free of defects? Are the two flange surfaces parallel and aligned properly? What is the type, specification, and installation method of the sealing gasket, and does its material meet the required standards? ； (7) Check whether there are sufficient flange bolts, whether their specifications are consistent, and whether there are any issues such as incomplete fastening, loose fastenings, cracks, or other damages. (8) The external markings shall be distinct, and the insulation and painting shall meet the specified requirements. 5. For the air cooler (1), is the nameplate complete, and does its content match that of the equipment? ； (2) Whether the installation is secure, whether the pillars are twisted, and whether the foundation bolts and static grounding are in good condition ； (3) Check whether the fan guard is in good condition, whether the motor, pulley, and fan are properly installed and aligned, whether the belt is too loose or too tight; rotate the fan to see if there are any collisions or uneven tension. (4) Manually operate the blinds to check whether the switches function smoothly, and whether the opening degree of the blinds matches the indication. Use the manual control system to increase or decrease the air pressure step by step, and observe the changes in the fan angle. (5) Check the pipe manifold for any deformation, bending damage, as well as cracks, sand holes, pitting, and rust. (6) Check whether the installation of the bellows plate meets the requirements, and any debris inside the bellows should be removed. (7) Check whether the finned tube is compressed, deformed, or bent. (8) Whether the platform and ladder meet the requirements and are convenient for operation and maintenance. (9) Are the vent ports, sampling ports, inlet and outlet pressure gauges, and thermometers in compliance with the production requirements and the design specifications? 6. Check whether the nameplate on container (1) is complete, and its contents should match those of the equipment. (2) Check the installation of the container, whether the support bases and shims are secure, and whether the foundation bolts and static grounding meet the requirements. (3) Check against the relevant drawings to ensure that the openings and connections of the container meet the process requirements, and that the flow direction of the valves, especially check valves and globe valves, is consistent with the process flow. (4) Whether the set pressure value of the safety valve meets the process requirements, and whether the lead seal is intact. (5) Whether the installation of level gauges, pressure gauges, temperature sensors, vent valves, etc., meets the requirements. (6) Whether the shell surface is smooth and straight, and whether there are any irregularities, deformations, or damages caused by poor manufacturing or damage during installation. (7) Check the detector wall and welds for cracks, slag inclusions, pores, and severe rust; the root undercut shall not exceed 0.5 mm. (8) Is the flange sealing surface smooth without scratches? Is the gasket installed correctly? Do the material specifications meet the requirements? Is the flange assembled parallel, without any misalignment or skewing? (9) Check whether the bolt specifications and materials of the connection flanges (including manholes and pipes) meet the requirements, whether the tightening force is consistent, and whether there are any under-tightened or loose bolts. (10) Check the installation of the internal components, ensuring that any debris has been cleaned away. (11) Whether the platform and ladder meet the requirements and are convenient for operation and maintenance. (12) Check whether all opening specifications, grades, and lengths meet the requirements. 7. Pipelines (1) Thoroughly inspect and verify the material and specifications of the pipelines and fittings. Check the materials and specifications specified in the piping design drawings, ensuring that welded steel pipes are not used in places where they are not appropriate, and that carbon steel is not used in areas where austenitic stainless steel should be used. A magnet can be used as a testing tool: pipes that are attracted by a magnet are made of carbon steel, while those not attracted by a magnet are made of austenitic stainless steel. Also, verify that the specifications and grades of the pipes and fittings meet the requirements outlined in the drawings. (2) Weld inspection: Each weld must meet the following requirements: A. No cracks, slag inclusions, sealing pores, or sand holes. B. The size of the weld tumor shall not exceed 1.5 mm. C. The edge bite shall not be greater than 0.5 mm. D. The root of the fillet weld must not be too short. E. Craters and droplets are not allowed. F. Spatter and weld marks from temporary assembly must be removed completely. G. The weld numbers and radiographic numbers in the pipeline are in accordance with the requirements. H. The flaw detection reports and fluoroscopy images must be complete and accurate; in particular, 100% imaging of the high-pressure pipe welds is required. I. The reinforcement height shall meet the following requirements: < Reinforcement height in mm, Base material thickness δ, Radiographic inspection – No radiographic inspection required when δ<9.5; 0.35, 1.5. For 9.5≤δ≤12.5: 3.2, 1.5. For 12.5≤δ≤25.0: 4.0, 2.5. For 25.0≤δ≤50.0: 4.8, 3.0. (3) Inspection of joint areas: A. The specifications, grade, and material of the flanges must comply with the requirements. B. The flanges must be installed parallel with consistent gaps; misalignment, gaps, skewing, or forced fitting are not allowed, and the sealing contact surfaces must not be damaged. C. The specifications, material, and model of the gaskets must match those in the piping diagram, and they must be installed in the correct positions. D. The specifications, material, and model of the bolts must match those indicated in the piping diagram; they must be installed correctly. The bolts must not be damaged, stripped, or bent, and the nuts must fit tightly around the bolts. E. For pipes connected by threads, at least five threads should be used, and there should be no slipping of the threads or any damage to them. (4) Inspection of the valve A. Check that the valve’s model and specifications match those of the piping, and that the nameplate is complete. B. The flow direction of the valve must meet the process requirements; special attention should be paid to check valves, as globe valves must not be installed in the reverse direction. C. The valve body and valve cover must be free of cracks, sand holes, and other defects that could affect strength. D. The valve body and valve cover must be free of cracks, sand holes, and other defects that affect strength. E. The material and specifications of the packing, as well as the valve cover gasket, must meet the requirements; they should be installed correctly with appropriate compression, without any misalignment, and the valve should open and close smoothly. F. The set pressure value of the safety valve meets the requirements, and the lead seal is intact. (5) Inspection of the process: carefully check the layout of the pipelines, the installation of valves, whether the positions of the openings meet the process requirements, and whether operation and maintenance are convenient and safe. (6) The pipelines should be properly placed on the pipe racks and support bases, tightened appropriately so as not to move around randomly; it is absolutely forbidden for any pipelines to protrude from their supports. (7) Check the pipeline for any damage from collisions during construction, bending, or severe corrosion. (8) Check whether the spring of the spring support can stretch and contract freely, and whether there is any sticking. (9) Check whether the \"8\"-shaped blind plates are complete and whether their material meets the requirements. (10) Are the venting at high points and discharge at low points in compliance with requirements? (11) Are the purging points for the pipelines properly and adequately provided? (12) For valves installed on high-altitude pipelines, check whether the opening and closing are convenient, and whether the operation platforms and ladders are safe and reliable. (13) Thoroughly inspect the heat tracing pipelines, as well as the steam supply points and condensate discharge points. (14) Clarify the origin and history of the buried pipelines as well as their anti-corrosion conditions. (15) Check whether the static grounding is proper. (16) Does the insulation layer meet the technical requirements, being complete, aesthetically pleasing, and of uniform thickness? (17) The painting condition shall meet the requirements. (18) When connecting pipelines to equipment, forceful centering should not be used. (19) Piping connected to equipment (especially pumps) shall not allow the weight of the piping to be borne by the equipment; proper support and suspension devices must be provided. 8. Pump (1): Are the nameplate details complete and accurate, and do the parameters match those of the equipment? (2) Check whether the foundation meets the construction quality requirements and whether there are any cracks in it. (3) Whether the installation of the pump is reliable, whether the anchor bolts are properly tightened and the static grounding is adequate, and whether the alignment of the pump has been completed. (4) Thoroughly inspect all components for signs of rust, damage from collisions, or damage caused by improper installation. (5) Check whether the lubricating oil system, seal oil system, and cooling system are functioning properly; ensure that the lubricating oil tank is clean, and that the level gauges, filters, flow control orifices, and valves are installed correctly. (6) Check whether the lubricating oil in the inlet, outlet pipelines of the pump and other auxiliary pipelines, as well as in the cooling system, is proper; whether the lubricating oil tank is clean; and whether the oil level gauge, filter, flow control orifice plate, and valves are installed correctly. (7) Check whether the installation of thermometers, oil level gauges, pressure gauges, safety valves and related instruments at various points meets the requirements, and whether they are easy to maintain and operate. (8) Check whether the gaskets and packing at each sealing point are installed properly. (9) Are the pump body, insulation, and paint in good condition? (10) Are the pumps and the floor clean, and are the water supply and drainage systems unobstructed? (11) Check whether the pipeline support is appropriate and whether it will impose additional load on the pump. (12) Is the switch position easy to operate? Is the switch flexible? Is the coupling box secure? 9. Inspection of utility systems. Utility systems include: fresh water, circulating water, demineralized water, medium and low pressure steam, condensate water, process air, instrument air, nitrogen, startup hydrogen, fuel gas, low-power flare lines, heat tracing steam pipelines, fire protection steam (water), rainwater, oily wastewater, and other such systems. (1) Check whether the boundary valves, metering orifice plates, and metering instruments of the utility system are configured in accordance with the design requirements and whether their quantities are complete. (2) Check whether the installation layout of the utility systems complies with the overall design of the plant. (3) Check whether the settings for low-point vents in the plant’s utility systems meet the design requirements. (4) Check whether the installation of steam drain traps and vent steam traps at all low points meets the design requirements. (5) Check that all flanges, valve orientations, and bolt installations in the plant’s utility systems are complete and meet the process requirements. (6) Check whether the flow direction of the heating steam pipelines and valves of the inspection device meets the design requirements. (7) Check whether the insulation of the plant’s utility systems is in good condition and meets the construction quality requirements. (8) Check whether the installation of purging steam, fire-extinguishing steam, and firefighting steam in the device complies with the design specifications. (9) Check whether the instrument air pipeline installation is complete. Check for any air leaks and ensure that the valve orientation is correct. (10) Check whether the industrial air ductwork is fully installed, for any air leaks, and ensure that the valve orientations are correctly assembled as required. (11) Check whether the fresh water pipeline is fully installed and whether the valve flow directions are correctly arranged. (12) Check whether the hydrogen, nitrogen, and air systems are in good condition. (13) Check whether the fuel gas pipeline and other accessories are fully installed and meet the design requirements. (14) Contact the relevant departments to check whether the pipelines for water, electricity, steam, fuel gas, raw materials, products, semi-finished products, etc., outside the device are fully installed, and whether various media can be supplied in or discharged from the device. (15) Check that all drainage traps in the device are present and properly aligned; clean any dirt from within the traps, and ensure that the underground pipelines are unobstructed. (16) Check that the open and hidden ditches within the device are clean, and that rainwater drainage is unobstructed. (17) Check whether the storage of fire protection equipment in the facility complies with safety regulations, and whether the fire exits are unobstructed. (18) Check whether the setup of the device platform and ladders meets the design requirements and safety regulations. (19) Check all power supply systems of the device, including lighting and emergency lighting in case of power outages, to ensure they are complete and in good condition. (20) Check whether the works related to the commissioning of the plant are fully completed and can meet the requirements for starting up the plant. (21) The testing and analysis are ready and can be deployed at any time to support production. (22) The instruments have been inspected and are ready for use; have the mechanical, electrical, and instrumentation teams made the necessary preparations to support production? (23) Prepare sufficient tools to open the valve. (24) Carry out all other inspection tasks. 10. Electrical (1) Has the construction of communication facilities been completed? Are the regular telephones and dedicated telephones functional, as well as the communication signals for various positions? (2) The lighting of the inspection device must meet the following requirements: A. The control switch must be easy to use and comply with safety standards. B. The lighting throughout the device meets the requirements for normal operation and inspection. C. Lighting fixtures and wiring must be installed firmly and in compliance with safety standards. (3) Check whether the grounding of the lightning protection facilities inside the device is proper. (4) Check all electrical equipment (excluding the distribution room) to ensure that the installation quality of their control switches, ammeters, etc. is good and that they are easy to operate. (5) Check the cable grounding of all electrical equipment (motors, electrical switches) for any defects such as damage or poor insulation caused by construction work. (6) Have all the alarm systems and indicator lights been installed, with no missed connections or similar issues? 11. Instruments (1) Conduct detailed calibration checks on the control points in accordance with the process instrument control procedure. (2) Check whether the installation locations of measurement points, thermocouples, pressure tapping points, measurement orifice plates, level gauge leads, etc., are correct and meet the process requirements. (3) The installation location and quality of the primary instruments and local control instruments, the measurement range of these instruments, and whether the connections to the secondary instruments are correct. (4) The model and specifications of the control valve should match those specified in the drawings; it must be installed properly, with its shaft straight and horizontal, without any bending. The valve should operate smoothly, and its travel distance should correspond to the markings on the scale. The positioner and handwheel must also be in good condition. Check whether the electrical converter is installed correctly, and whether the output signal of the secondary meter matches the input signal of the actuator. 12. Fire protection facilities: (1) Check the pipes of the fire water system against the drawings to ensure that the installation of fire pumps meets the requirements, that flanges and joints are properly sealed, and that valves and handwheels operate smoothly. (2) Check whether the fire-fighting equipment such as hoses at various fire stations, steam hoses, gas fire extinguishers, and fire wrenches are complete. (3) Check whether the piping of each fire-fighting steam system meets the requirements. As for the inspection of the installation quality, it shall be carried out in accordance with the inspection items for process pipelines, to ensure that the locations and quantity of each steam connection meet the fire-fighting needs and facilitate operation. (4) Check whether the fire alarm system and communication facilities have been installed and are ready for use. (5) Are the fire roads completed and unobstructed?

1 Purpose of inspection: Before the hydrogenation unit is put into operation for trial runs, a comprehensive inspection of the project quality must be carried out in accordance with the design requirements, to ensure the safe start-up and operation of the unit. 1.1 Check whether the construction and installation of the device meet the design requirements. 1.2 Check for any missing project items. 1.3 Check for any process modification projects. 2. Inspection contents: 2.1 Overall equipment: ① The floor of the equipment should be intact in terms of its vertical structure; sewer pits, drainage ditches, underground tanks, underground cables, and cover plates for utility trenches must all be present and in good condition. ②The office building, control room, power distribution room, compressor room, as well as the roads and floors are in good condition. The lighting and communication systems meet the design requirements. ③The construction of pipe bridges, pipe racks, pipe supports, pipe hangers, pipe clamps, insulation systems, heat tracing systems, ladders, guardrails, frames, platforms, etc., meets the required standards, being firm and undamaged. ④The fire-fighting equipment is complete and functional. 2.2 Process pipelines ① Check each process pipeline according to the process flow diagram, following its path, to verify whether the connections to and from the equipment meet the requirements. ②Whether the material, diameter of the process pipelines, as well as the materials of valves, flanges, gaskets, bolts, and nuts meet the design requirements. ③Alloy pipelines, fittings, and accessories in high-temperature and high-pressure systems should be identified using spectroscopy. Ultrasonic thickness testing should be conducted on both alloy pipelines and thick-walled carbon steel pipes used in such systems, to ensure the accuracy of both the material composition and wall thickness; a dedicated person should be assigned to carry out these inspections. ④Check whether the valves, check valves, safety valves, control valves, steam traps, flow orifice plates, pressure gauges, blind flanges, and other components on the process pipeline are installed correctly; ensure that all valves have been pressurized, that the packing in the valves is properly installed, that the valves operate smoothly, and that all bolts are tightly tightened. ⑤The pipeline has passed the hydraulic test, the welds meet the design specifications, and the construction records are complete. ⑥The process pipelines are anticorrosived, painted, insulated, and heated as specified in the design. ⑦Check the process pipeline for any incorrect wiring. 2.3 Pumps and motors: ① The pump and motor models meet the design requirements. ②The foundation base of the pump is stable, intact, and smooth, with the anchor bolts fully tightened. Combined pollution discharge force. ③The oil cup, oil level gauge, check valve, pressure gauge, protective cover, and grounding wire meet the design requirements and are reliable and functional. ④The pump is fully painted and shiny. ⑤ The inlet and outlet valves of the pump, as well as the pipelines for cooling water, seal oil, flushing oil, and lubricating oil, are all properly installed. ⑥The trial operation seal is properly installed, and the mechanical seal is ready. ⑦The inlet and outlet valves, check valves, and filters of the pump are installed correctly. 2.4 Compressors ① Check the installation quality of the new hydrogen compressor and the circulation compressor in accordance with the installation drawings. ②The pressure gauges, thermometers, control levers, control panels, load regulators, etc., have all been calibrated and are functioning properly. ③The oil injector and lubrication station work well. ④The nitrogen seal line, cooling water, and grounding wire are properly installed. ⑤Import/export valves, check valves, safety regulations, filters installed correctly – flexible and easy to use. ⑥The compressor oil pressure and temperature self-protection system is well-adjusted and functional. ⑦The base and frame are solid and intact. The bolts are fully tightened. 2.5 Heating Furnaces: The tube materials and structures of both the hydrogenation reaction furnace and the distillation reboiler meet the design requirements. ②Are the steam superheater and exhaust fan installed correctly? ③The furnace lining and chimney show no severe cracks or peeling, and the expansion joints meet the requirements. ③Negative pressure gauge, temperature measurement point, viewing port, explosion-proof door, fire suppression hose, burner, air valve in good condition; pressure measurement tubes unobstructed. ④Flue dampers, the furnace pressure control system is well tuned. 2.6 Tower ① The internal components of the tower are complete and not detached, and the material quality and installation standards meet the requirements. ②Check the installation records to ensure that the levelness of the trays and the verticality of the tower meet the design requirements. ③Safety regulations, relief valves, check valves, pressure gauges, level gauges, manhole flanges, gaskets – all must be installed correctly and in good working condition. The level gauge conduit is unobstructed. ④The tower foundation is complete and solid, with bolts fully tightened. ⑤Inspect each tray, reflux port, feed port, reboiler drawoff port and counter-current port, as well as the oil collection tank, from top to bottom in the tower. Level port. 2.7 Cooling equipment: ① The materials, specifications, and models of the hydrogen-facing high-pressure heat exchangers, coolers, and air coolers meet the design requirements. ②Heat exchangers of the same specification, model, but different materials should not be installed in a misaligned manner. ③The foundation and supports are complete and secure. ④Import and export pressure gauges, thermometers, insulation, and grounding meet the requirements. ⑤All valves, flanges, gaskets, plug valves, etc. meet the requirements, and the valves operate smoothly. ⑥Are the air coolers installed in accordance with the design requirements? 2.8 Pressured vessels ① The vessel material and the installation of components shall meet the design requirements. ②The container should not be deformed; the foundation and supports must be secure, with bolts tightened fully. ③Pressure gauges, gaskets, level gauges. Relief valves are in place and fully utilized; the safety valves have been set to the required pressure and sealed with lead seals. Especially for high and low pressures, the safety valve at the compressor outlet must be flexible and reliable in operation. ④The raw material filter must be installed in accordance with the design requirements. 2.9 Instruments ① All instruments in the entire installation are properly installed, meet the design requirements, and the orientation of the control valves is correct. ②All control circuits must be calibrated and found to be satisfactory. ③All control valves are flexible and easy to use. ④All temperature, pressure, flow rate, level, and interface level indications are correct. ⑤The heating furnace, feed pump, hydrogen compressor, and the emergency venting safety interlock are all functioning properly. 2.10 Circulating water station ① The circulating water pump is installed in accordance with the design requirements. ②The fans are installed in accordance with the design requirements. ③The construction of the pool meets the design requirements.

The replies from the 5th, 7th, and 8th floors were quite good; they were all very comprehensive. Those in need can refer to it, but it still needs to be customized according to the actual conditions of one’s own device. I would like to express my gratitude here to the 5th, 7th, and 8th floors! ! ! Please continue to support:handshake in the future.

For the first inspection, the more issues there are, the better. Encourage all technical staff and operators to conduct inspections in different areas; it’s even possible to set a requirement for how many issues each person must identify, or to offer a reward for each issue found. One must be aware of the overall responsibility; if it isn’t corrected properly the first time, it will still be one’s own problem later on.

First, a management convening system must be established to determine who will convene the meeting, which units will participate, and to clarify the roles and responsibilities； Second, determine the inspection plan and standards. Third, determine the inspection items: 1. Inspection of process pipelines 2. Inspection of valves 3. Inspection of reactors, towers, containers, and heating furnaces 4. Inspection of heat exchange equipment 5. Inspection of compressors and pumps 6. Inspection of instruments and control systems 7. Overall inspection of the plant 8. External inspection of the plant